Fire resistant fascia gutter system and coverings using the same

ABSTRACT

A covering having insulated panels is meant to prevent or slow the spread of fire. Each panel has a top cover; a fire-prevention layer having a fire-retardant material, a fire-resistant material, or a combination of both; and an insulation layer. The fire-prevention layer is located, at least partially, between the top cover and the insulation layer. When there are two or more insulated panels, they interlock at a joint and form a plane.

BACKGROUND

The invention relates to systems used to construct coverings and means to make the covering resistant to catching fire. The systems include insulated panels 2 that interlock with one another along abutting edges. These systems tend to be heavily used the covering industry. These designs have proven to be very reliable and long lasting, however they may be susceptible to catching fire.

The benefits of the insulated panels 2 are that they insulate the area that they are covering and are fairly strong. The insulated panel 2 coverings come with interlocking panels 2. The panels 2 typically comprise of two metal layers (an top cover 24 and a bottom cover 22) with an insulated material located (insulation 21) in the middle. The panels 2 may come in standard sizes (e.g. 2 feet (0.6096 meter) in width and 4 inches (10.16 centimeters) in height) with interlocking components. This system has a long working life and comes with the industry standard of a 20 year warranty.

Joints 9 are the weakest part of the system in both waterproofing and fire resistance. Many times only an external seal 96 is applied to the joint 9 and the external seal 96 can be flammable. Other times, internal seals 92 are also applied, and they too can also be flammable. Both the external seals 96 and the internal seals 92 will typically deteriorate before the panels 2 will. The interlocking joints 9 have several designs, but work on the same basic principle. The internal seals 92 will be applied during, or before, the construction process as well as the external seal 96. This will help elongate the life of the covering by limiting exposure to the sun to the internal seals 92. Thus when the external seal 96 fails; there are several internal seals 92 that will extend the life of the covering. As mentioned before, these internal seals 92 are also often flammable. As such, the joint 9 has susceptibility to catching fire. In other insulated panels 2, only one seal is present and is applied along the uppermost junction of the joint 9, the external seal 96. In these panels 2, the external seal 96 can catch fire and spread and/or drip into the joint 9. Fire can also move into the ducts 95 when internal seals 92 are present, resulting in their melting and fetching fire. The main concern with these structures is that the insulation 21 will catch fire, causing the entire structure to catch. The insulation 21 can catch fire from the heat from embers landing (causing the insulation to catch fire) on the top cover 24 and heat caused from seals catching fire.

The elements are not kind to external and internal seals 92. Eventually the rain and exposure will deteriorate all seals. This is partly because fire will enter from the top and accumulate in these channels 91, once the external seal 96 is breached. As illustrated by FIGS. 9 and 10 , fire can enter the channel 91.

Very recently, fire codes have now created a need where one was not previously present. The codes now require that the structures, in order to be approved for installation, must resist catching fire after being exposed to fire on the surface for a certain amount of time. A structure need not be fireproof, but must be able to show a resistance to catching fire over a set period of time under certain conditions.

BRIEF DESCRIPTION OF THE DRAWINGS

Many aspects of the embodiments can be better understood with references to the following drawings. The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the embodiments. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.

FIG. 1 shows an embodiment of a covering;

FIG. 2 shows a cross-section of an embodiment of a covering;

FIGS. 3 and 4 show embodiments of a covering employing a rafter tail;

FIGS. 5 and 6 shows a cross-section of an embodiment of a covering;

FIGS. 7 and 8 show embodiments of the fascia gutter;

FIGS. 9 and 10 shows joint assemblies according to the prior art and the progression of water, represented by the arrows, in the joint assemblies;

FIG. 11 is a front view of an embodiment of a covering of with an insulated panel and a joint;

FIGS. 12 and 13 show an embodiment of a covering;

FIG. 14 shows an embodiment having structural member; and

FIG. 15 shows an embodiment having a column attachment.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring to FIGS. 1 and 2 , an embodiment with rafters 3 and insulated panels 2 is shown. There are caps 4 present on the rear and sides of the panels 2. The rafters 3 are connected to the fascia gutter 1, and the caps 4 are present on the side of the panels 2. A debris guard 6 is located near the front of the panels 2. The debris guard 6 comprises a base 61 and a screen 65. The base 61 is secured to the panels 2 and/or caps 4. The debris guard 6 increases its profile such that it is greater than the gap 7 defined by the panels 2 and the protrusion 16. In some embodiments, the base 61 is merely an extension of the screen 65. In other embodiments, the base 61 is a solid piece of material. The debris guard 6 helps prevent debris, such a leaves or embers, from entering and thus clogging or providing fuel for fire. The rise of the debris guard 6 from the base 61 to the overhang 64 allows leaves to be easily blown away and embers to be either held away from the insulated panel 2 or directed away from the gutter.

In one embodiment, the debris guard 6 comprises an end 62, a protrusion bend 63, and an overhang 64. The overhang 64 extends over the edge of the protrusion 16. This will help ensure that the clogging debris will not be allowed to slip around the front side of the debris guard 6. In some embodiments the overhang 64 will actually make contact with the fascia gutter 1. The end 62 of the debris guard 6 also extends past the end of the protrusion 16 as well. The protrusion bend 63 is located between the end 62 and the overhang 64. In some embodiments, the protrusion bend 63 is located at the vertex of a sharp bend or a rounded bend. The protrusion bend 63 can be in contact and abut the protrusion 16.

The insulated panels 2 comprise of insulation layer 21, a bottom cover 22, a fire prevention layer 23, and a top cover 24. In some embodiments, the insulation layer 21 comprises foam, fibrous material, fiber glass, or a combination thereof. In some embodiments, the insulation layer 21 is categorized as a fire-resistant material and/or a fire-retardant material. In some embodiments, the bottom cover 22 comprises metal, composite, plastic, wood, or a combination thereof. In some embodiments, the bottom cover 22 comprises aluminum. In some embodiments, the top cover 24 comprises metal, composite, plastic, wood, or a combination thereof. In some embodiments, the top cover 24 comprises aluminum. The fire-prevention layer 23 comprises a fire-resistant material, fireproof, and/or a fire-retardant material. In some embodiments, the fire-prevention layer 23 comprises mineral wool, gypsum, asbestos, perlite, corriboard, calcium silicate, sodium silicate, potassium silicate, treated lumber, treated vegetable fiber, fire-retardant treated wood, concrete, cement render, intumescent, glass, magnesium oxide, asbestos substitutes, or a combination thereof. In some embodiments, the fire-prevention layer 23 comprises asbestos, endothermic material, vermiculite, polystyrene, ceramic, gypsum, calcium silicate, perlite, or a combination thereof. In some embodiments, the fire-prevention layer 23 comprises of a material available under the trade name DENSDECK.

Referring to FIGS. 5 and 6 , some embodiments comprise of a fire-prevention layer 23 on the end of the panel 2. The fire-prevention layer 23 on the end can help protect, prevent, or delay the insulation layer 21 from catching fire. It is also understood that in some embodiments, there is not a fire-prevention layer 23 on the end of the panel 2.

Referring to FIGS. 7 and 8 , the fascia gutter 1 comprises a front member 11, a bottom member 12, a rear member 13, a ledge 14, a protrusion 16, and an opening 17, defined by the ledge 14 and the protrusion 16. The opening 17 is large enough to allow the panels 2 to be inserted and have a gap 7 between the panels 2 and the protrusion 16. The gap 7 allows for water that collects on the top surface of the panel 2 to enter the fascia gutter 1. In some embodiments the gap 7 is ½ inch (1.27 centimeters) or greater. It is also understood that the gap 7 can be of any size. There is also a receiving gap 8 that exist between the panel 2 and the front member 11. The receiving gap 8 will allows the water that flows through the gap 7 to flow down into the receiving space. Some standard thicknesses for insulated panels 2 are 4 inches (10.16 centimeters) and 3 inches (7.62 centimeters), and embodiments that can be used with those insulated panels 2 can have an opening 17 of 4.5 inches (11.43 centimeters) and 3.5 inches (8.89 centimeters) respectively. In some embodiments, the end of the insulated panel 2 has a fire prevention layer 23 caping the end of the insulation layer 21. This could help prevent the insulation from catching if fire were to enter the facia gutter 1.

As can be seen in the embodiment shown in FIG. 9 , the joint 9 employees the used of external seal 96 and internal seals 92 in the channel 91. As discussed, fire can possibly erode the external seal 96 and enter onto the channel 91. Like a fire source located on the top cover 24, the fire prevention layer 23, will shield the insulation layer 21 from heat and delay it catching fire. There is also a choke point 27 that will help prevent fire from spreading further into the channel 91. Also, in some embodiments, the duct 95 is not filled with insulation layer 21 and that will help delay and/or prevent the insulation of the insulated panel 2 to the left from igniting. In some embodiments, the duct 95 is filled, partially or completely, with the insulation layer 21.

As can be seen in the embodiment of FIG. 10 , the joint 9 is similar to the joint 9 shown in FIG. 9 . The joint 9 does not have the internal seals 92.

As is also shown in FIGS. 9 and 10 , the top cover 24 can extend down to form an internal wall 25 and an internal floor 26. In some embodiments, the fire prevention layer 23 can extend along the internal wall 25 and/or the internal floor 26. The fire prevention layer 23 can help protect the insulation from melting and/or catching fire.

As can be seen in FIG. 11 , in one embodiment, insulated panels 2 are employed. As seen from the front of the fascia gutter 1, the joint 9 is shown in shadow. Thus, if fire were the enter the channel 91, the duct 95 provides an air space to insulate the insulation layer 21. Water that happens to enter into anyone of the channels 91 and or ducts 95 is free to vacate into the fascia gutter 1. This will decrease the time that the internal seals 92 are exposed to the water and or water is present in the ducts 95. Thus, having the joint 9 exposed to the opening 17, the fascia gutter 1 prevents or greatly reduces the standing water within the joint 9 and pathways for fire to spread.

It is believed that less time the internal seals 92 are exposed to water and standing water, the longer they will maintain their integrity. The longer the integrity of the joint 9 is maintained, the longer the covering will last without maintenance and the greater amount of time the resistance to fire will be maintained.

In some embodiments, the external seal 96 is a fire resistant, fireproof, and/or fire retardant. In some embodiments, the internal seals 92 are fire resistant, fireproof, and/or fire retardant. In some embodiments the external seal 96 and/or the internal seals 92 comprises mineral wool, gypsum, asbestos, perlite, corriboard, calcium silicate, sodium silicate, potassium silicate, treated lumber, treated vegetable fiber, fire-retardant treated wood, concrete, cement render, intumescent, glass, magnesium oxide, asbestos substitutes, or a combination thereof. In some embodiments the external seal 96 and/or the internal seals 92 comprises asbestos, endothermic material, vermiculite, polystyrene, ceramic, gypsum, calcium silicate, perlite, or a combination thereof. In some embodiments, the external seal 96 and/or the internal seals 92 comprise a fire-resistant material, fireproof, and/or a fire-retardant foam, caulk, and/or sealant.

Also, if any water happens to get into the body of the insulated panel 2, they are also open to the fascia gutter 1. In some embodiments, conduits (not shown) will be located in the insulated panels 2 (e.g. on the bottom of the insulation layer 21) to facilitate removal of water that happens to enter the insulated panels 2.

In some embodiments, the insulating material of the insulated panels 2 will include antibacterial, antimicrobial substances, and/or additives to help limit the growth of bacteria and/or microbes in and/or on the insulating material.

As can be seen in FIGS. 5-8 , some embodiments of the fascia gutter 1 includes a guiding groove 15 located on the ledge 14. During construction, the builders typically are inserting the ledge fasteners 81, blindly through the panels 2. The guiding groove 15 helps guide the ledge fasteners 81 so that when they come into contact with the ledge 14, they are secured to the ledge 14. The width and shape of the guiding groove 15 is not limited (e.g. any concave shape). If the ledge fastener 81 misses the ledge 14, it will likely not be connecting the panels 2 to anything. In some embodiments, the protrusion 16 also has a guiding groove 15 (not shown).

The protrusion fastener 82 extends from above the protrusion 16 to the panels 2. However the gap 7 must be maintained. In some embodiments, it is incumbent upon the skill of the installer to maintain the gap 7. In other embodiments, a spacer (not shown) is located between the protrusion 16 and the panels 2. Examples of spacers include, but are not limited to, one or more nuts, one or more washers, and tubes. The spacer can be located only in the proximity of the protrusion fastener 82. Yet in other embodiments, a portion of the debris guard 6 can serve as a spacer (not shown). In some of those embodiments, the debris guard 6 can have a stepped configuration between the protrusion bend 63 and the end 62. The protrusion 16 will rest upon the step.

Referring to FIGS. 3 and 4 , some embodiments include a rafter tail 5 that can be attached to the fascia gutter 1 along the front member 11. In some embodiments the front member 11 is flat with an embossed finish, giving the appearance from the front of being a wood like structure. Then the rafter tail 5 can be installed to give the look from the front and below that a full rafter is employed. This will help maintain the natural look of the covering, e.g. a wood covering, while allowing for longer spans in between rafters 3. The location of the one or more rafter tails 5 can be set as desired. The rafter tails 5 can be attached by know methods including, but not limited to, one or more fasteners (not shown) and/or adhesives.

As can be seen in FIGS. 12 and 13 , additional fascia gutters 1 can run parallel to the joints 9 and can be, or not be, in communication with the fascia gutter 1 that runs transverse to the joints 9. While not shown, debris guard 6 can run along the length of the parallel fascia gutters 1 as they are able to accept water that has collected on the covering. This can increase the efficiency of evacuating water from the covering.

As can be seen in FIG. 14 , some embodiments can include a structural member 100. The structural member 100 can be an insert that is separate from and has a shape that at least partially corresponds with the fascia gutter 1. In other embodiments, the structural member 100 is integral with the fascia gutter 1 or bonded thereto. The structural member 100 can be of the same material of the fascia gutter 1 or a different material than the fascia gutter 1. The structural member 100 can increase the strength of the fascia gutter 1. While a column can be attached to the fascia gutter 1 without a structural member 100, the span between columns can be increased when a structural member 100 is employed to the same fascia gutter 1. The thickness and material of the structural member 100 can be selected according to need.

As can be seen in FIG. 15 , in one embodiment, a column attachment 110 can be connected to the fascia gutter 1 as a means to attach the fascia gutter 1 to a column. In some embodiments, the column attachment 110 is secured to the fascia gutter 1 by a fastener. In other embodiments, the column attachment 110 can be secured by an adhesive. Yet in other embodiments, the column attachment 110 is integral with the fascia gutter 1. The column attachment 110 has a shape that at least partially corresponds to the column and is able to slide therein. In some embodiments, the attachment is barely able to slide into the column and has a frictional fit with the column. In some embodiments, fasteners and/or adhesives can be used as well to secure the column attachment 110 to the column. The downward length of the column attachment 110 can vary. A greater length can increase the stability of the connection.

In some embodiments, the fascia gutter 1 is roll formed from aluminum sheets. In other embodiments, the fascia gutter 1 and the rafter tails 5 can have an embossed texture on the external faces thereof. In one embodiment, the front member 11 is 6.5 inches (16.51 centimeters), the bottom member 12 is 3 inches (7.62 centimeters), the rear member 13 is 2 inches (5.08 centimeters), and the ledge 14 is 0.75 inches (1.905 centimeters). In accommodating panels 2 of different thickness, the length of the front member 11 may, or may not, be altered, and the height of the protrusion 16 relative to the bottom member 12 may, or may not, be altered. The length of the front member 11 may remain consistent for panels 2 of different sizes, and other dimensions can be altered.

By using the fascia gutter 1 with insulated panels 2 the columns to be placed further on the periphery of the covering. In embodiments employing a structural member 100, the spacing of the columns can be increased; while, in order to maintain the classic appearance of a wooden covering, rafter tails 5 can be applied directly to the fascia gutter 1. The structural member 100 can be made from extruded aluminum or galvanized steel.

Depending on the embodiment, certain steps or methods described may be removed, others may be added, and the sequence of steps may be altered. Those skilled in the art will now see that certain modifications can be made to the apparatus and methods herein disclosed with respect to the illustrated embodiments, without departing from the spirit of the instant invention. And while the invention has been described above with respect to several embodiments, any element and/or step described in reference to any particular embodiment is hereby disclosed to be associated with any other embodiment of the invention. It is understood that the invention is adapted to numerous rearrangements, modifications, and alterations, and all such arrangements, modifications, and alterations are intended to be within the scope of the invention. 

1. An apparatus comprising: two or more insulated panels, each insulated panel comprising: a top cover; a fire-prevention layer comprises a first material selected group consisting of a fire-retardant material, a fire-resistant material, or a combination thereof; and an insulation layer; wherein the fire-prevention layer is located, at least partially, between the top cover and the insulation layer; wherein the two or more insulated panels form two or more interlocking panels, and the two or more interlocking panels are coupled together at a joint, and the two top covers substantially define a plane.
 2. The apparatus of claim 1, further comprising a debris guard coupled to each top cover and extending over the joint.
 3. The apparatus of claim 1, wherein the joint comprises a channel, and the channel is in communication with facia gutter.
 4. The apparatus of claim 1, wherein the joint further comprises an internal seal; the internal seal and the two or more interlocking panels define a duct; and the duct is in communication with a facia gutter.
 5. The apparatus of claim 1, wherein the joint further comprises an external seal; wherein the external seal is located between each top cover and the external seal comprises a second material selected group consisting of a fire-retardant material, a fire-resistant material, or a combination thereof.
 6. The apparatus of claim 1, wherein each insulated panel further comprises a bottom cover, and the insulation layer is located between the fire-prevention layer and the bottom cover.
 7. The apparatus of claim 1, wherein each insulated panel further comprises an interior wall extending at a first angle from the top cover, and an internal floor extending at a second angle from the interior wall, wherein the first angle and the second angle are an angle greater than zero degrees (0°).
 8. The apparatus of claim 7, wherein the fire-prevention layer is at least partially located between the interior wall and the insulation layer, the internal floor and the insulation layer, or both.
 9. The apparatus of claim 1, wherein the top cover and the insulation layer define a duct, wherein the duct.
 10. The apparatus of claim 8, wherein each insulated panel defines a duct, and the duct is empty space.
 11. The apparatus of claim 8, wherein the top cover, of one of the two or more insulated panels, abuts, or nearly abuts, the internal floor, of another of the two or more insulated panels, to form a choke point.
 12. The apparatus of claim 1, wherein the joint further comprises one or more internal seals; wherein the one or more internal seals are located between the two or more insulated panels, and the one or more internal seals comprises a third material selected group consisting of a fire-retardant material, a fire-resistant material, or a combination thereof.
 13. An apparatus comprising: an insulated panel comprising: a top cover; a fire-prevention layer comprising a first material selected from the group consisting of a fire-retardant material, a fire-resistant material, or a combination thereof; and an insulation layer; wherein the fire-prevention layer is located, at least partially, between the top cover and the insulation layer; and a fascia gutter, the fascia gutter comprising: a front member; a bottom member; a rear member; a ledge; and a protrusion; wherein the bottom member joins the front member to the rear member; the front member, the bottom member, and the rear member define a receiving space; the ledge is coupled to the rear member; an opening is defined by the ledge and the protrusion; the channel is in communication with the receiving space; the insulated panel is in contact with the ledge and not in contact with the front member; and a gap is defined by the insulated panel and the protrusion.
 14. The apparatus of claim 13, further comprising a groove, wherein the groove is defined in the ledge.
 15. The apparatus of claim 13, further comprising a second insulated panel and the insulated panel and the second insulated panel form two interlocking panels, and the two interlocking panels are joined at a joint; the joint comprises a channel, and the channel is in communication with the receiving space; and the two interlocking panels are in contact with the ledge and not in contact with the front member.
 16. The apparatus of claim 15 wherein the joint further comprises one or more internal seals; wherein the one or more internal seals are located between the two interlocking panels, and the one or more internal seals comprises a third material selected group consisting of a fire-retardant material, a fire-resistant material, or a combination thereof.
 17. The apparatus of claim 15, wherein the joint further comprises an external seal; wherein the external seal is located between each top cover and the external seal comprises a second material selected group consisting of a fire-retardant material, a fire-resistant material, or a combination thereof. 